WO2015058887A1

WO2015058887A1 - Electrical connection bracket for a motor-vehicle electrical system line

Info

Publication number: WO2015058887A1
Application number: PCT/EP2014/068039
Authority: WO
Inventors: Heinz-Georg Gottschlich; Martin Schloms
Original assignee: Auto-Kabel Management Gmbh
Priority date: 2013-10-25
Filing date: 2014-08-26
Publication date: 2015-04-30
Also published as: MX2016005291A; CN105723564B; ES2721254T3; MX358698B; US20160250984A1; EP3061153A1; CN105723564A; EP3061153B1; DE102013017660A1; DE102013017660B4; US9475440B2

Abstract

The invention relates to an electrical connection bracket for a motor-vehicle electrical system, comprising a cable (2) having a metal conductor (4) and comprising an electrical tap (12) electrically and mechanically connected to the conductor (4). A decentralized electrical-system structure is made easier in that the tap (12) is formed of a metal flat part (20) and a metal connection pin (12) bonded to the flat part (20) and that the flat part (20) is connected to the conductor (4) in a bonded manner in a connection region (10) of the conductor (4), wherein the connection region (10) is arranged between the ends of the cable (2).

Description

Electrical connection console for vehicle wiring system

The subject matter relates to an electrical connection console for a motor vehicle electrical system line comprising a cable with a metallic conductor and an electrical tap that is electrically and mechanically connected to the conductor. The subject also relates to the use of such a connection console.

In a motor vehicle electrical system it is necessary, starting from one

Main power line, which is directly connected to the positive pole of the battery to realize electrical outlets to consume. Due to the large number of electrical consumers to be connected in a vehicle electrical system is a wide

Branching of the wiring system required. Some consumers need great power from the battery, and thus need to use cables with large ones

Cable cross-sections are connected to the distribution network. Groups of consumers often need to be secured by a common fuse, on the other hand, it is also necessary, starting from the main power line to provide a plurality of each hedged cable strands.

The tap of electrical energy from the main energy line is not readily possible. On the one hand, such a tap is associated in each case with a contact resistance and thus ohmic losses and, on the other hand, there is an increased risk of corrosion at the taps.

In addition, when using aluminum cables, the electrical tap is always exposed to the risk that by oxidation of the aluminum conductor of the

Contact resistance is large and the electrical power loss leads to this contact resistance to an undesirable heating of the line. Based on these problems, the object was based on the object of providing an electrical connection console, with which a decentralized vehicle network topology is made possible. This object is achieved by an electrical connection console according to claim 1. Especially in motor vehicle electrical systems preferably in those in which the battery in the rear of the vehicle and the prime mover, in particular the starter of the internal combustion engine, but also possibly an electric motor for the drive, are arranged in the engine compartment, the main battery line runs from the rear to the front of the vehicle. This can be done by an underground installation of the battery cable or by an interior installation of the battery cable. Along this

Battery string can be realized with the help of the subject terminal console a plurality of electrical outlets in a particularly simple manner. In particular, if the battery string is formed from an aluminum conductor, in particular an aluminum ladder, it is problematic to arrange connection consoles on such conductors. With the help of the objective solution, it is possible in a non-insulated area, in particular in a remote from the line ends center region of the cable, a metallic flat part with a

cohesively formed with the flat part metallic connecting pin to be arranged on the metallic conductor. For this purpose, an electrical tap is formed by the metallic flat part and the connecting bolt. The flat part becomes

cohesively connected to the conductor in the connection area. The connection region lies between the ends of the cable and is preferably arranged in a middle region of the cable. In particular, the connection area is remote from the distal ends of the cable. By materially arranging the flat part on the conductor, an enlarged connection area can be realized, via which a sufficiently high current flow with low electrical losses is possible. In particular, the conductor of the electric cable is insulated and in the

Connection area is the conductor free of the insulation. Thus lies the connection area between two isolated areas of the conductor. In this stripped area, according to one embodiment, the flat part can be materially connected to the conductor. If several stripped areas are provided, one or more connection consoles can be provided along the path of the cable, via which electrical taps are possible. Especially if the cable is from the

Main battery string is so diverse electrical taps on the

Battery string can be made without negatively affecting the conductance of the battery line as such by otherwise necessary interruptions. The taps do not lead to increased electrical power loss along the cable, since the cable is not interrupted by the taps.

By means of a cohesive connection, the tap, or its metallic flat part, can be connected to the cable of the cable. In this case, the cable remains intact and its conductance is not affected substantially. So it is possible to lead a one- or two- or multi-piece cable from the battery to the engine compartment, in particular to the starter or the electric motor in the engine compartment, which is not or only marginally affected by taps in its electrical conductivity of each section. The insulation of the cable is such that it completely encloses the conductor in the insulation sections. The insulation is preferably formed of a non-conductor, in particular a plastic, such as PVC or silicone.

According to one embodiment, it is proposed that the electrical conductor is a round conductor. Preferably, the electrical conductor is rigid and thus not plastically deformable due to its own weight in particular. It is also suggested that the conductor is formed of aluminum or an alloy thereof. In particular, E-aluminum, such as aluminum 99.5 can be used for the conductor. In order to make the pad between the flat part and the conductor in the connection area as large as possible, it is proposed that the conductor in the Connection area has a flat area. In particular, a planum of the conductor is formed in the connection region, on which the flat part can be cohesively arranged. This area is made in accordance with an embodiment by cutting or non-cutting forming.

In particular, a compression or compression, in particular a radial compression or compression can be used to form the planar region of the conductor. Preferably, the forming can take place directly during a joining process between the conductor and the flat part. Thus, e.g. when welding by means of e.g. Ultrasonic the sonotrode and the anvil are used both for welding the components as well as for simultaneous shaping of the subgrade by upsetting. A Reibpunktschweißen is possible, here the

Welding tools can simultaneously enable welding and forming. The cohesive connection of the flat part to the conductor is simplified in particular when it is formed from a solid material. Unlike

Stranded conductors, the conductor is made of solid material in one piece and a welding, in particular by means of ultrasound, is favored, since then not individual strands can be brought into vibration whereby the welding energy could be compensated. Rather, in a solid material during welding, the entire welding energy is introduced into the contact surface between the flat part and the conductor in the connection area and the materials melt.

Depending on the use of the material of the conductor is preferably the flat part of an electrically similar, in particular the same metallic

Material formed. For example, if the conductor is formed of copper or an alloy thereof, the plate may also be formed of copper. Since, however, especially in the use of aluminum, the subject

Connecting console is advantageous, it is also proposed according to an embodiment that the flat part of aluminum or alloys thereof is formed. By using an electrically similar or the same metal for the conductor as well as the flat part, a sorted connection is ensured in the area of the connection console between the tap and the ladder. Contact corrosion is thus prevented or reduced to a minimum. On the other hand, the connection console is intended to provide an electrical tap. This tap is used by outgoing cable from the tap. These may be formed, for example, of copper. In order to facilitate the electrical tap on the terminal console, it is proposed that the terminal stud may be formed of copper or alloys thereof. However, it is also possible a departure to an electrical contact part made of aluminum, so that then the terminal bolt may also be formed of aluminum.

The contact corrosion between the flat part of aluminum and the

Connecting bolt can be reduced by the connecting bolt is made of steel or stainless steel. In this case, the contact corrosion between the terminal bolt and the flat part is negligible. By suitable

Insulation measures, the contact point between the terminal bolt and the flat part from environmental influences, especially against water are protected and thus the risk of corrosion can be reduced.

In order to equip the connecting bolt for connection to a cable lug or other cable end, it is proposed that this is tin-plated and / or umickelt. A particularly good connection between the flat part and the conductor is possible if this is produced by means of ultrasonic welding. By the

Ultrasonic welding breaks up a possibly existing aluminum oxide layer on the conductor and the resulting welding knot is largely free of aluminum oxide. As a result, the contact resistance is in the range of

Welding node compared to conventional welding processes reduced. According to one embodiment, it is proposed that the connecting bolt by means of friction welding, in particular rotational friction welding or

Reibpunktschweißen, but also by means of arc welding, is connected to the flat part. By the friction welding of the connecting bolt to the flat part can also be broken any existing aluminum oxide layer on the flat part and the contact resistance between the flat part and the

Connection bolts are kept small.

According to one embodiment, it is proposed that the flat part on the side facing away from the connecting bolt is materially connected to the conductor. On the one side of the flat part of the conductor thus can cohesively connected to the flat part and on the other side of the flat part of the connecting bolt. Since the conductor is connected to the flat part on the side facing away from the connecting bolt, the conductor obstructs the connection of an electrical connection to the

Connection bolt not. The output direction of an electrical connection to the connecting bolt is thus freely selectable and can be done in particular at an angle as well as parallel to the course of the conductor.

According to one embodiment, it is proposed that the flat part, in parts of the bolts and the conductors are encased with an insulation. In particular, the insulation is such that it not only surrounds the flat part, parts of the bolt and the conductor, but extends beyond the insulation of the conductor out. Thus, a complete enclosure of the flat part, the part of the bolt and the conductor is made possible. The ingress of moisture is largely prevented by the insulation. As a result, the transitions between the conductor and the flat part, respectively between the flat part and the connecting bolt are protected from ambient moisture.

In order to allow an electrical connection to the connecting bolt, the connecting bolt is free from the insulation at its end remote from the flat part. It is possible that the insulation in the area of the bolt is such that it can be picked up a closure, in particular in the form of a cap is formed. Thus, the end of the bolt can be covered with an insulating cap, and in the event that a connection to the bolt is to take place, the cap can be removed. In order to avoid incorrect polarity during installation of the electrical system and in particular to contact the correct bolt for the respective outlets, it is proposed that the insulation in the region of the remote from the flat part end of the connecting bolt Poka Yoke is mechanically coded. By a certain shape of the extent of the insulation of the bolt in the region of the end remote from the flat part can be ensured that only certain types of connection plugs can be connected to the bolt. If, for example, the inner circumference of a plug is not congruent with the outer circumference of the insulation on the bolt, a plug connection can be prevented. This can prevent misconnections. In particular, the coding takes place by shaping the outer circumference of the insulation in the region of the end of the bolt.

For example, in a recording within the

To fix the vehicle body, it is proposed that an edge length of the flat part is greater than the diameter of the line, in particular greater than the diameter of the cable. In particular, square and rectangular shapes of the flat part have been found to be advantageous.

The subject connection bolt can be used in particular in power lines, for example battery lines, in particular high-current lines, in particular motor vehicle battery lines.

The article will be explained in more detail with reference to drawings showing an exemplary embodiments. In the drawing show:

Fig. La a cross section of a cable; Fig. Lb is a view of a stripped cable;

Figure lc is a view of a stripped, compressed cable. FIG. 2 is a view of a cable according to FIG. 1; FIG.

3a shows a view of a connecting bolt according to an embodiment;

Fig. 3b is a view of a connecting bolt according to another

Embodiment;

Fig. 3c is a view of a connecting bolt according to another

Embodiment; Fig. 3d shows a view of a connecting bolt according to another

Embodiment;

4 shows a view of a bolt according to FIG. 3b; 5a shows a plan view of a flat part according to an embodiment;

5b is a plan view of a flat part according to an embodiment;

5c is a plan view of a flat part according to an embodiment;

6 is a view of a flat part connected to a connecting bolt.

7 shows a view of a connection console according to an embodiment; 8 shows a view of a connection console according to FIG. 7; 9 shows a cross section of an insulated connection console;

10 shows a view of a connection console according to FIG. 9 with a fuse box connected thereto;

Fig. IIa is a plan view of a mechanical coding of a

Terminal stud;

Fig. IIb is a plan view of a further mechanical coding of a

Terminal stud;

Fig. 11c is another plan view of a mechanical coding of a

Terminal stud.

FIG. 1 a shows an electrical cable 2 with a metallic conductor 4 and an insulation 6.

The metallic conductor 4 is preferably as a solid material and in particular resistant to bending. The conductor 4 is preferably a round conductor. The material of the conductor 4 is

preferably aluminum, in particular aluminum 99.5. The bending stiffness of the cable 2 arises when the cable 2 due to its own

Weight does not plastically deform. It's a bigger force than that

Weight force necessary to plastic deformation of the cable. 2

bring about.

The insulation 6 is preferably made of PVC or silicone.

As shown in FIG. 1b, in the case of an objective connection console, the cable 2 is stripped in a central region, that is to say remote from its respective distal ends, so that a stripped region 8 is formed. In the stripped area 8, the conductor 4 is free of the insulation 6. After the stripped region 8 has been produced, the cable 2 or its conductor 4 can be compressed or pressed, so that its radius or its diameter is reduced and a planar

Connection area 10 is formed, as shown in Figure lc. The connection region 10 is suitable for connection of the flat part, as will be shown below. It is also possible and advantageous that upsetting occurs directly during the joining of the line with the flat part. It can be in a process step both the

cohesive joining and upsetting done.

FIG. 2 shows a view of a cable 2 according to FIG. 1c. It can be seen that the conductor 4 is a round conductor and flat in the region of the connection region 10

is trained. This can be done by upsetting or pressing. Of the

Terminal area 10 is located in the stripped area 8, which is remote from the distal ends of the cable 2.

FIG. 3a shows a connecting bolt 12. The connecting bolt 12 shown in FIG. 3a is cylindrical and formed from a solid material. In particular, the connecting bolt 12 may be formed of stainless steel. However, it is also possible to form the terminal bolt 12 made of copper, aluminum or alloys thereof. The terminal bolt 12 can be formed by turning or cutting a rod.

FIG. 3b shows a connecting bolt 12, which has a terminal at its one end

Terminal lug 14, to which, for example, a clamping element of an electrical connection can be clamped. In particular, can

For example, a terminal in the form of a battery terminal to the

Terminal lug 14 are clamped. FIG. 3 c shows a connection bolt 12, in which one end is provided with a thread 16. To such a connection bolt 12, for example, an electrical connection can be screwed.

FIG. 3d shows a further connecting bolt 12, which has an opening 18, in particular in the form of a bore, at its end. Through this opening 18, for example, a screw with an electrical connection can be made in which a screw is pushed through an opening 18 and / or screwed there.

FIG. 4 shows a connection bolt according to FIG. 3b in a view. It can be seen that the cylindrical bolt 12 in the region of the terminal lug 14 has a smaller radius and is formed, for example, for receiving a clamping element.

FIG. 5 a shows a plan view of a flat part 20. The flat part 20 is preferably formed from the same material as the conductor 2. Preferably, the flat part 20 is formed of aluminum or alloys thereof, in particular of aluminum 99.5. It can be seen in FIG. 5 a that the flat part 20 has a square cross-section.

However, as can be seen in Figure 5b, the cross section of the flat part 20 may also be rectangular.

Also, an oval cross-section, as shown in Figure 5c, is possible. Round cross-sections or other cross-sectional shapes of the flat part 20 are also possible and can be adapted depending on the purpose of the terminal console.

FIG. 6 shows a view of a flat part 20 with a bolt 12 welded thereto. The bolt 12 is preferably welded to the flat part 20 by means of rotational friction welding and a weld 22 forms between the bolt 12 and the flat part 20. The weld 22 is preferably free from Alumina and the contact resistance between the pin 12 and the flat part 20 is in the range less μθΐιιη.

FIG. 7 shows the connection of the flat part 20 to the conductor 4. It can be seen that the flat part 20 already connected to the bolt 12 is connected to the conductor 4 in a material-locking manner. This connection can for example by means of a

Ultrasonic welding process can be produced. It forms a weld 24 between the flat portion 20 and the conductor 4. For ultrasonic welding of the flat portion 20 with the conductor 4, it is possible, the bolt 12 in a

Clamp the ultrasonic sonotrode and press the conductor 4 by means of an anvil against the underside of the flat part 20. If the flat part 20 is then subjected to ultrasound, the weld seam 24 forms between the flat part 20 and the conductor 4. The planum can also be produced here. It is therefore not necessary to produce the plan in a preceding process step. By ultrasonic welding, an aluminum oxide layer, which is formed either on the conductor 4 and / or the flat part 20 is broken and the

Transition resistance over the weld 24 is also in the range less μθΐιιη. It can be seen that the edge length of the flat part 20 is greater than the diameter of the line 4. It can also be seen that the line 4 on the side facing away from the bolt 12 of the flat part 20 with the flat part 20 is welded. To protect the welds 22 and 24 from environmental influences is the

Connection console, as shown in Figure 9, with an insulator 26 overmolded. The insulator 26 protrudes beyond the insulation 6 of the cable 2. The insulator 26 surrounds the flat part 20 and the bolt 12 at least partially and thus insulates the welds 22, 24 from environmental influences. In the region of the flat part 20 facing away from the end of the bolt 12, this, as shown in Figure 9, free from the insulation 26. A cap 28 may be provided to protect the bolt 12 at least temporarily against environmental influences.

FIG. 10 shows a view of an overmolded connection console according to FIG. 9.

In addition to the connection console, a fuse box is shown in FIG. The fuse box is connected via an electrical conductor to the connection console or the bolt 12. The electrical conductor is screwed or clamped to the bolt 12, for example, and thus provides an electrical connection with the conductor 4. The electrical potential of the conductor 4 can thus be tapped in the fuse box 30 and from there branches can branch off to the consumers.

To allow the connection of consumers to the bolt 12 during assembly

simplify and in particular to prevent being wrong

Connection pin 12 electrical outlets are provided, the insulator 26 is mechanically coded in the region of the end of the bolt 12 by shaping. Figure IIa shows a mechanical coding in the form of a square. The insulation 26 is square shaped in the region of the end of the bolt 12, so that, for example, only square plug or plug faces can be plugged onto the bolt 12.

The mechanical coding of the insulation 26 may, for example, also, as shown in Figure IIb, be formed by recesses in the insulator 26. The contour of the recesses may be different, so that with different recesses different mechanical shapes and codes are possible.

Also, the extent of the insulation 26 in the region of the end of the bolt 12 may be selected differently, for example, as shown in Figure 11c in triangular shape with a projection 32. Depending on the coding only suitable connectors can be plugged onto the bolt 12 and thus can be ensured that the right outlets are connected with the right bolts. With the help of the connection console shown a particularly simple electrical tap of a power line is possible. The power line as such is hardly affected electrically and its line resistance remains essentially unaffected by the number of connection consoles. Furthermore, the connection consoles can be provided at the desired positions along the line, so that a decentralized distribution of energy in the electrical system is possible. Several fuse boxes and outlets can be connected as required at different locations within the vehicle in a particularly simple manner with the power line. An assembly of the cable is thus individually adaptable and is thus a vehicle of any kind.

Claims

P a n t a n s p r e c h e

Electric connection console for a motor vehicle electrical system comprising a cable (2) with a metallic conductor (4), and

an electric tap electrically and mechanically connected to the conductor (4),

characterized,

the tapping is formed from a metallic flat part (20) and a metallic connection bolt (12) formed in a materially closed manner with the flat part, and in that the flat part (20) is formed in a connection region (8) of the conductor (4).

is integrally connected to the conductor (4), wherein the connection region (8) between the ends of the cable (2) is arranged.

Electrical connection console according to claim 1, characterized in that the cable (2) has an insulation (6) of the conductor (4) that the

Connection region (8) is arranged in a stripped region arranged between two insulation sections of the insulation (6) and in that the flat part (20) in the connection region (8) is materially connected to the conductor (4).

Electrical connection console according to claim 2, characterized in that the insulation (6) completely surrounds the conductor (4) in the insulation sections.

Electrical connection console according to one of the preceding claims, characterized in that the conductor (4) is a round conductor and / or that the conductor (4) made of aluminum or an alloy thereof is formed and / or that the conductor (4) in the region of the connection region a flat area (10) and / or that the area (10) by cutting or non-cutting forming, in particular by radial compression, of the conductor (4) is formed and / or that the conductor (4) is formed of solid material.

Electrical connection console according to one of the preceding claims, characterized in that the flat part (20) made of aluminum or

Alloys thereof is formed and / or that the connecting bolt (12) made of aluminum, copper or alloys thereof, steel or stainless steel is formed and / or that the connecting bolt (12) is tinned and / or unterickeled.

Electrical connection console according to one of the preceding claims, characterized in that the flat part (20) is connected by means of ultrasonic welding to the conductor (4).

Electrical connection console according to one of the preceding claims, characterized in that the connecting bolt (12) by means of

Friction welding, in particular rotational friction welding with the flat part (20) is connected.

Electrical connection console according to one of the preceding claims, characterized in that the flat part (20) on the connection pin (12) facing away from the side with the conductor (4) is integrally connected.

Electrical connection console according to one of the preceding claims, characterized in that the flat part (20), in parts of the connecting bolt (12) and the conductor (4) with an insulation (26), in particular to above the insulation (4) of the conductor (4 ), are preferably encapsulated.

Electrical connection console according to one of the preceding claims, characterized in that the connection bolt (12) is free from the insulation (26) at its end remote from the flat part (20).

11. Electrical connection console according to one of the preceding claims, characterized in that the insulation (26) is mechanically coded at least in the region of the flat part (20) distal end of the connecting bolt (12) Poka Yoke, in particular that the extent of the insulation (26 ) is mechanically coded in the region of the end remote from the flat part (20) of the connecting bolt (12) by shaping.

12. Electrical connection console according to one of the preceding claims,

characterized in that at least one edge length of the flat part (20) is greater than the diameter of the conduit (4), in particular larger than the diameter of the cable (2).

13. Electrical connection console according to one of the preceding claims,

characterized in that the flat part (20) has a square or rectangular shape.

14. Use of an electrical connection console according to one of

preceding claims in a power line, in particular in a motor vehicle battery line.